Building system and method

ABSTRACT

A building system can comprise wall, floor, and/or ceiling panels. A first profile with two cavities extending along different sides of the profile can be used to connect similar panels together. A second profile can be used to connect dissimilar panels. A plurality of fastening clips can be used to lockingly engage a wall panel at one end and one of either a wall panel, a floor panel, or a ceiling panel at the other end. The building system can be configured to not require other fasteners besides the clips and profiles to hold the panels together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. ProvisionalApplication No. 61/535,785, filed Sep. 16, 2011, entitled “BUILDINGSYSTEM AND METHOD,” which is incorporated by reference herein in itsentirety and is to be considered a part of this specification.

BACKGROUND

1. Field

Certain embodiments disclosed herein relate generally to buildingsystems, in particular to modular building systems. The buildingssystems can be collapsible and reusable and can be used for manydifferent purposes. The building systems can employ a unique fasteningsystem to connect, combine, and hold in the place the various componentsor modular units of the building system.

2. Description of the Related Art

Portable building systems are used in many different situations andlocals as varied as classrooms, bathrooms, sheds, construction sites,and emergency relief hubs. Many portable building systems aremanufactured and assembled in one location, and then shipped in whole orin half to the needed location. It is often impracticable to assemble onsite, whether to assemble entirely or primarily on site. This preventsthe use of portable building systems in some situations in which theywould be ideal or forces people to use tent-like-structures that may notadequately address the needs of the users. For example, it may beimpossible or impractical to transport a pre-assembled building into thebackcountry and/or to a disaster area where shelter for whatever purposeis needed.

SUMMARY

Accordingly, there is in the need of the art for improvements toportable building systems, including improvements to fastening systemsto connect, combine, and hold in the place the various components ormodular units of the building system. These improved systems may solveor address some of the problems described above.

Preferably, a building system includes a plurality of walls, a ceilingand a floor. The walls, ceiling and floor can be held together viaprofiles or extrusions and clips that engage with a wall at one end andeither the ceiling or floor at the other end. One or more inserts canalso be used that fit within a groove or notch in a wall, ceiling, orfloor. In such embodiments, the clips can have engagement portions(e.g., crimped ends, protrusions, hooks, etc.) that connect to and/orfit within the inserts.

A building system of some embodiments can comprise wall, floor, and/orceiling panels. A first profile with two cavities extending alongdifferent sides of the profile can be used to connect similar panelstogether. A second profile can be used to connect dissimilar panels. Aplurality of fastening clips can be used to lockingly engage a wallpanel at one end and one of either a wall panel, a floor panel, or aceiling panel at the other end. The building system can be configured tonot require other fasteners besides the clips and profiles to hold thepanels together.

In some embodiments, a building system can comprise, a series a wallpanels, a series of floor panels, and a series of ceiling panels. Eachpanels can have one or more of a respective wall slot, floor slot, andceiling slot. A first profile can comprise two cavities extending alongdifferent sides of the profile, each cavity configured to receive apanel from the same series together. A second profile can be forconnecting panels from one series to another series together, the secondprofile having a shape different from the first profile and comprisingtwo cavities positioned essentially perpendicular with one another, thefirst cavity configured to receive at least one of either the floorpanels or the ceiling panels, and the second cavity configured toreceive at least one of the wall panels such that in the assembledconfiguration the wall panel will rest on and be above the at least onefloor panel or the ceiling panel will rest on and be above the wallpanel. A plurality of fastening clips can be used where each clip isconfigured to lockingly engage a wall slot at one end and one of eithera wall slot, a floor slot, and a ceiling slot at the other end, whereinthe building system does not require other fasteners besides the clipsand profiles to hold the panels together.

According to some embodiments, a building system can comprise a series awall panels, a series of floor panels, a series of ceiling panels, afirst profile being in the shape of an I-beam for connecting panels forconnecting panels from the same series together, a second profile, and aplurality of clips. The second profile can be for connecting panels fromone series to another series together. The plurality of clips can beconfigured to lockingly engage a wall panel at one end and one of eitherthe wall panels, floor panels, and ceiling panels at the other end. Thebuilding system can be made to not require other fasteners besides theclips and profiles to hold the panels together.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are depicted in the accompanying drawings forillustrative purposes, and should in no way be interpreted as limitingthe scope of the inventions, in which like reference characters denotecorresponding features consistently throughout similar embodiments.

FIG. 1 is a perspective view of a building.

FIG. 2 is a view of the bottom of the building of FIG. 1.

FIG. 3 shows a view of a floor unit.

FIGS. 4 and 4A illustrate a profile.

FIGS. 5 and 5A illustrate another profile.

FIG. 6 illustrates a partially assembled building including a floor andwalls of the building.

FIGS. 7 and 7A illustrate another profile.

FIGS. 7B and 7C illustrate cross-sections of addition embodiments ofprofiles.

FIG. 8 shows a clip and corresponding inserts.

FIG. 9 is a cross-sectional view showing an assembled clip andcorresponding inserts.

FIG. 10 shows a partially assembled building from the top looking down.

FIG. 11 is an illustration of parts of the roof section and/or ceilingof a building.

FIG. 12 illustrates a cross-section of a building.

FIG. 13 shows a partially assembled shipping container.

FIG. 14 illustrates a shipping container that can be used as a building.

FIG. 15 shows another embodiment of a building system.

FIG. 16 shows a beam construction.

FIG. 17 shows a view looking inside a building.

FIG. 18 is a detail view of an embodiment of a roof and ceilingstructure.

FIG. 19 is a partially expanded view of the building system of FIG. 15.

FIG. 20 illustrates a corner of a building system.

DETAILED DESCRIPTION

A building system and method can include a collapsible reusablebuilding. The building system can include a plurality of panels that canbe connected together to form the building. The panels can include avariety of different sizes such that the building can also take manyforms. The building can also include a number of profiles used toconnect and seal the spaces in between the panels. The building systemcan also include clips or fasteners that can be used to connect andsecure the panels together, including the profiles.

Certain examples of the building systems and methods are outlined below.A collapsible reusable building can also be portable such that all thecomponents can be shipped together for easy and simple assembly on site.In some embodiments, the building system can be assembled into abuilding in a short amount of time, such as 30 minutes, and with limitedto no tools. Advantageously, the building system can comprise a seriesof modular units that can be combined in different configurations. Thecomponents of the building system can also be modular, such that theyare easily interlockable and do not require the use of tools forassembly. As one example which will be explained in more detail below,the roof system can include a series of individual units which can beconnected to form the roof.

Looking now to FIG. 1, a building 10 is shown. The building can be usedfor any of many purposes, such as being a shed, storage facility, livingquarters, bathroom, dining facility, sleeping quarters, refrigerator,medical unit, ice fishing shack, etc. For ease of discussion, thebuilding unit 10 will be described in three sections; namely, adiscussion of the base unit or foundation 3, the walls 5 and the roof 7.It will be understood that any and all of the components of the buildingsystem 10 can be used individually or separately, or in combination withother features and systems. For example, the roof 7 can be used on otherstructures and with other building systems. In addition, the walls 5 canbe used with other styles and designs and systems of roofs 7 andfoundations 3. The foundation 3, walls 5 and roof 7 can also be othershapes than those shown, including round, triangular, octagon, curved,etc. There may also be layers, levels, steps, etc.

Looking now to FIGS. 2 and 3, the base or foundation 3 will bedescribed. It will be understood that the base of foundation 3 can takemany forms. The base or foundation 3 generally forms the bottom of thebuilding to which the walls 5 can be attached. The foundation 3 can bemade up of a series of one or more floor units 30. Each floor unit canbe combined with other floor units to create the floor of a building.Each floor unit 30 can also be used individually. As can be seen in FIG.3, each floor unit 30 can be made up of a floor panel 36 and a system ofjoists and/or beams 32 to raise the floor panel off of the ground. Thejoists and/or beams 32 may or may not be attached to the floor panel(s)36. In addition, the joists and/or beams 32 may or may not beinterconnected. With the floor panels raised off the ground, access isprovided to the bottom of the floor panels. Among other benefits, thiscan allow one or more clips to be attached to the floor panel and a wallpanel, as will be described in more detail below. The joists 32 can bemade of any of many different materials, such as metal and wood. In apreferred embodiment, the joists 32 are made of metal. In someembodiments, joists 32 or other materials can be used to level the floorpanels or further raise the floor panels off of the ground, such as toallow water to pass under the building.

As can be seen with reference to FIG. 2, the floor panels 30 can be heldtogether with one or more joining bridges 34. The joining bridges 34 canbe made to easily assemble and disassemble from the joists 32 of theindividual floor panels 30. For example, a system of screws and wingnuts can be used to secure the joining bridges 34 to the joists 32.

The floor panels 30 can also be held together with a system or series ofprofiles 12. FIG. 4 illustrates a cross-section of one of the profiles12. The profile 12, similar to other profiles described herein, cansecure the panels together and also provide waterproofing and othersealing functions to seal the spaces in-between the panels such that theelements from the environment cannot pass through. As can be seen, thecross-section of the profile 12 is generally in the form of an I-beam,or the shape of an H, although other configurations are also possible.Another way to describe the cross-section is that of two C-pockets orcavities 21 that are on opposite sides of the profile. The profile 12,similar to the other profiles described herein, can be formed such thatthe panel fits within the profile in the C-pocket or cavity 21 in a snugor snap-fit type connection. Alternatively, there may be a small gapbetween the panel and the profile on one or more sides of the connectionbetween the profile and the panel. In some embodiments, the profiles canbe made of plastic, such as ABS or PVC. Other materials such as fiberglass can also be used. The profiles may be manufactured by extrusion orpultrusion, among other methods.

Referring now to FIG. 4A, the profile 12 can include one or more notches18. The notch 18 can comprise an area of the profile where some of thematerial of the profile has been removed. As shown in FIG. 4A, one endof the profile 12 has a notch removing all but the bottom side of theprofile at one end. In some embodiments, the profile may have one ormore notches 18. For example, both ends may have notches 18. In additionor alternatively, a notch may be located along the length of theprofile. Referring back to FIG. 2, it can be seen that in the illustrateembodiment, notches 18 are found on both ends of the profile 12 in thefloor or foundation 3.

The base or foundation 3 can also include a second profile 14 (FIG. 2).The profile 14 can be used to connect the base or foundation 3 with thewalls 5. Referring now to FIGS. 5 and 5A, one example of the secondprofile 14 is shown. It will be understood that the description of theprofile 14 in relation to the foundation or base 3 and the walls is orcan be equally applicable to the connection between the walls and theroof 7. As can be seen in FIG. 5, the profile 14 can include twoC-pockets or cavities, identified herein as a first cavity 20 and asecond cavity 22. The first and second cavities can be aligned withopenings that are perpendicular to one another. Also as shown, thecavity 20 can be positioned below the cavity 22. This can allow for thecavity 20 to be slid onto or connected to the floor panel 36. This way,the floor panel can also serve as support for the wall sections whichwill be slid into or connected to the cavity 22. Although not shown, theprofile 14 may also include one or more notches 18.

After the base or foundation 3 has been assembled and at least oneprofile 14 attached, a user can begin construction of the wall section5. The walls can be constructed placing one panel within the cavity orchannel 22 followed by additional profiles and panels, as will bedescribed. FIG. 6 shows a building with a partially constructed wallsection 5. As can be seen, the wall section is made up of a series ofwall panels 50. The wall panels can be different sizes, can servedifferent purposes, and can include any number of different features.For example, the wall panel 50 may include one or more cavities or holes52, 54, 56. The cavity 52 may serve as a door cavity. The cavity 54 canserve as a window, and the cavity 56 can receive other features, such asan air conditioning unit, heating unit, ventilation, or other featureswhich require a hole or cavity to pass through the panel 50.

As can be seen, the wall panels 50 are connected through a series ofprofiles. As has been described, a profile 12 can be used to connect thewall panels 50, similar to the manner in which the profile 12 connectsthe floor panels 36. In some embodiments, of the wall section 5, theprofiles 12 may include one or more notches 18. For example, the profile12 may have a notch 18 located at the top of the profile 12. A thirdprofile 16 can also be used at the corners of the wall unit 5.

Referring to FIGS. 7 and 7A, the third profile 16 will now be described.The profile 16 can include two cavities or channels 24 which are alignedperpendicular to one another. The profile 16 also includes a cavity 26.As can be seen, cavity 26 forms the corner of the wall unit and also thecorner of the profile 16. Other configurations are also possible. Forexample, the profile 14 can be used instead of the profile 16 to formthe corners of the wall unit 5. As can be seen in FIG. 7A, the profile16 can include one or more notches 18.

Though three designs of profiles 12, 14, and 16 have been described, itwill be understood that the profiles can take on one of many differentshapes. In their basic configuration, a profile has two C-pockets orcavities that are connected to thereby connect two separate panels. Ashas been mentioned, those panels can include at least wall panels, floorpanels, and ceiling panels. The relationship between the two C-pocketsor cavities can vary greatly. For example, referring to FIG. 7, an angleAlpha (α) can be used to define this relationship. In FIG. 7, α is equalto about 90 degrees. This is in contrast to FIG. 4, where alpha is notshown because it is equal to about 0 degrees. FIGS. 7B and 7C show thecross-sections of two additional embodiments of profiles 16′ and 14′. InFIG. 7B, α′ is shown as being less than 90 degrees and in FIG. 7C, α″ isshown as being greater than 90 degrees. A profile similar to profile 16′could be used, for example, when forming a circular, octagon, pentagon,hexagon, etc. shaped building. In some embodiments, α can be equal toabout 30, 45, 60, 75, 90, 100, 120, 135, and 150 degrees A profilesimilar to profile 14′ could be used for example, when forming atriangular, parallelogram, trapezoid, etc. shaped building. Variousshaped profiles can also allow for the creation of distinct shapes,alcoves, nooks, etc. It will be understood that the panels can also beshaped to allow the building to be shaped as such. Thus, the wall panelsmay be rounded or curved and then floor and ceiling panels may be largerone end as compared to another, such as in a trapezoid, or a piece ofpizza shape. The other shapes can also be used.

Other features shown in the profile 16′ includes a rounded back side 27and a gap 29 in one of the walls 31 of the cavity 24. It ill beunderstood that any of the profiles could also include these features.Another feature shown in the profile 14′ is that the cavity 20′ does notextend out as far as the cavity 20 in profile 14 shown in FIG. 5.

As has been mentioned, the panels can be connected to one another with aseries of fasteners or clips 28 such as that shown in FIG. 8. Thefasteners or clips 28 can be the same or similar to those described inapplication Ser. Nos. 13/558,162 filed on Jul. 25, 2012 and 61/511,951,filed on Jul. 26, 2011 which are both incorporated by reference hereinand made a part of this specification. The panels, such as the floorpanels, wall panels or, as will be described below, the ceiling panels,can include one or more slots or cavities 38 (FIGS. 3, 6, 10) into whicha clip 28 can fit into. The clips 28 can be sized and shaped to engagewith slots or cavities 38. The fastener can be L-shaped such that oneend will connect to a first panel, such as a wall panel, and the otherend can connect to a second panel, such as a floor panel. The fastenercan use a spring force to secure the panels together.

Inserts 130 can be configured to at least partially fit within the slotsor cavities 38. An insert 130 can also be placed within the slot tofurther seal and help secure the fastener in the fastened position.Preferably, the clips 28 are configured to engage with inserts 130installed in the slots or cavities 38. Engagement between the clips 28and the inserts 130 and/or slots 38 can secure adjacent panels to eachother and enable secure construction of the building system. The inserts130 can be the same or similar to those described in application Ser.Nos. 13/558,162 filed on Jul. 25, 2012 and 61/511,951, filed on Jul. 26,2011 which are both incorporated by reference herein and made a part ofthis specification.

FIG. 8 illustrates a clip 28 and two corresponding inserts 130. Eachinsert 130 can include a base 132 and a flange portion 134. The backside of the base 132 can be configured to fixedly and/or releasablyengage with a slot 38 in a panel. The front side of the base 132 can beconfigured to engage with and receive one of the engagement features152, 154 of the clip 28.

The clip 28 has a first engagement feature 152 configured to engage withan insert 130 and/or with a slot 38 in the panel. The clip 28 can have asecond engagement feature 154 configured to engage with an insert 130and/or with a slot 38 in another panel. In some embodiments, one of thefirst and second engagement features 152, 154 is configured to engagewith an insert 130 and the other is configured to engage directly with aslot 38 in a panel. It will be understood that though a particular styleof clip is described, any of number of different clips could be used.For example a CLIP-LOK Brand clip or other type of clip could be used.In addition the building system could use one or more different stylesor types of clips. Inserts may or may not be used with any of the clips.

One or both of the first engagement feature 152 and second engagementfeature 154 can include one or more clip release features 156. In someembodiments, the clip release feature 156 comprises one or moreprotrusions, tongues, or lips, which may include flat unbent portions onthe end of the first and/or second clip portions 152, 153. The cliprelease feature 156 can be used to assist with the removal of thesubject clip 28 and/or with removing already assembled clips 28. Theclip release feature 156 is shown extending from the end of the clip,between the two U- or V-shaped engagement features 154. The clip releasefeature 156 can have one of many different shapes.

As shown, the clip release feature 156 has a low profile and extendsover the slot 38 and/or over the inner cavity of the insert 130. As canbe seen with reference to FIG. 9, the clip release feature 156 canextend into the opening in the insert, but preferably does not extendpast, or completely cover the opening. This allows a user to release theclip by engaging the clip release feature 156 with one of a variety oflevers. This can be done without the use of any special tools. Forexample, another clip, a screwdriver, a shovel, a crowbar, etc. can beadvanced under the clip release feature 156 into the groove or insertand then used as a lever to pop the clip out of engagement with thegroove or insert. It will be understood that the clip release feature156 can function in other or similar ways, at different locations. Forexample, the clip release feature 156 can be located near the end of theclip, but not extending over an opening. The clip release feature 156can be structured and/or positioned such that a lever can still beplaced under the clip release feature 156 and the clip pried off. Inother embodiments, the clip release feature 156 can be pulled away fromthe container to release the clip.

As mentioned, the clip can use a spring force to secure the panelstogether. Returning to FIG. 8, an angle θ between the first clip portion151 and the second clip portion 153 can be greater than about 45° and/orless than about 135° when the clip 28 is in a disconnected state (e.g.,not engaged with inserts 130 or slots 38). In some embodiments, theangle θ is approximately 75° when the clip 150 is in the disconnectedstate. As illustrated in FIG. 9, clips 28 can be used to adjoin twosides 110 of an object at an angle β. Preferably, the angle θ betweenthe first and second clip portions 151, 153 for a given clip 28 is lessthan the angle β between the two sides 110 of the object being connectedby such a clip 28. In such cases, the clip 28 must be widened (e.g., theangle θ must be increased) in order to fit the clip 28 onto the twosides 110. As such, the bending stress in the clip 28 due to thewidening of the clip 28 can bias the first and second engagementfeatures 152, 154 into the slots 38 and/or inserts 130 on the adjoiningsides 110. Such a biasing force helps the clip 150 to stay in place andsecure the two sides 110 to each other.

It will be understood that the clips 28 can be attached to the buildingat any point after the various panels have been put together.Preferably, the clips are attached after the corresponding panels havebeen placed next to one another and within the respective profile. Ifinserts are used, they can be inserted at any time prior to attachmentof the clips.

Once the base or foundation 3 has been assembled and the walls 5 havefurther been assembled onto the foundation or base 3, the roof and/orceiling 7 can then be assembled. In some embodiments, another buildingunit can be attached to the assembled walls and base so that both unitscan share the same roof.

Returning to FIG. 6, it can be seen that in some embodiments, the topsof some of the wall panels 50 can include one or more slots or channels58. A beam can be placed within corresponding slots on opposite wallpanels 50. The beam can provide additional structural support for theceiling and roof.

Looking now at FIG. 10, it can be seen that the ceiling panels 72 havebeen placed on the wall unit 5. It can also be seen that profiles 14have been used to connect the ceiling panels to the wall unit 5.Although not shown, profiles 12 or other styles of profiles can also beused to connect the individual ceiling panels 72 to one another. Theceiling panels can be open as shown with holes passing therethrough orclosed. Preferably, the ceiling panels 72 provide a surface around thetop perimeter of the walls unit 5. This provides structural support tothe building and also provides a surface to connect the clips betweenthe wall panels and the ceiling panels.

The configuration shown in FIG. 10 provides many benefits. For example,the cube or rectangular structure with panels on each side has greatstructural integrity. In addition, a base unit, as shown in FIG. 10 canutilize a variety of different style roofs. For example, a solid, angledroof can be used as is illustrated elsewhere herein. Alternatively, aflat solid roof; a flat vinyl, a plastic, a foam, or other material andor shape roof, can be used. In addition, the roof can be transparent toallow sun light into the building. In some embodiments, the panels 72can serve as both the ceiling and the roof. In addition, in someembodiments, the panels 72 can be provided with additionallypreassembled roofing material such that installing the ceiling and theroof is performed simultaneously. It will be understood that manydifferent types and styles of roofs can be used.

FIG. 10 illustrates the fasteners or clips 28 that have been secured tothe panels 72 and 50 as was discussed previously. As can be seen, a slotor cavity 38 in the panels 72 and 50 is used to connect the two ends ofthe clip or fastener 28. Although only a limited number of clips 28 areshown, it should be understood that clips 28 can be used throughout theassembly, such as to hold the panels 50 together at the corners, andalso the panels 50 and panels 36 at the wall and base or floor. In someembodiments, the clips 28 connect on top of or over the profiles 14and/or 16 and/or other profiles.

The ceiling panels 72 can include one or more holes or cavities 74. Theholes or cavities 74 can be used to attach to or provide additionalfeatures in the ceiling. For example, a ceiling plug can be attached toor within the space 74. The ceiling plug may include lights, fan units,ventilation, or other features. In some embodiments, the ceiling plugcan be thin ABS material that is thermo formed to the desired shape.

Turning to FIGS. 11 and 12, another embodiment of a roof and/or ceilingsection 7 is shown. In this embodiment, it can be seen that the ceilingplugs 76 and 78 are illustrated. Ceiling plug 76 can simply plug thehole or space 74, whereas ceiling plug 78 includes one or more lightingunits 80. The lighting units can include any type of lighting system,such as LED, fluorescent, or incandescent. The lighting units 80 canalso be powered with various different types of systems, includingbatteries, solar power, and electrical connections to a separateelectrical source, such as city power.

The roof and/or ceiling section 7 can include a roof unit 82. The roofunit 82 can be a preassembled unit including shingles or other roofouter covering surfaces, awnings, one or more trusses, flashings, andother ceiling members. In some embodiments, the roof unit can have apolyurea coating on an outer surface. In some embodiments, the roof unit82 can be formed such that one side has a flashing 83 that extends pastthe rest of the unit so that when combined with another roof unit 82,the flashing will overlap with the second unit, creating a sealed andwaterproofed roof structure.

The roof unit 82 can also include a hole or cavity 84. In the assembledcondition, the hole 84 can be lined up above the hole 74 on the ceilingpanel. This can allow the ceiling plugs, such as 76 and 78, to alsoconnect to the roof unit 82. As has been mentioned, the ceiling plugscan provide many different features.

The roof unit can be secured to the ceiling panel 72 in many differentways. For example, as just mentioned, the ceiling plug 76 or 78 can beused to secure the roof unit 82 to the ceiling panel 72. In someembodiments, a clip or fastener 28 can be used to secure the roof unit82 and the ceiling panel 72. For example, one end of the fastener 28 canfit within a channel or slot 38 and the other end can wrap around tocontact the bottom of the ceiling panel 72, as can be seen in FIG. 12.As can also be seen in FIG. 12, the roof and/or ceiling section 7 canalso include a series of beams 86. As discussed with reference to FIG.6, the wall panels 50 can include one or more slots or channels 58 andthe beams 86 can be placed within corresponding slots on opposite wallpanels 50 to provide structural support for the ceiling and roof. Thesize of the beams 86 can depend on many features including potentialsnow-load.

One advantage of the above described roof design is that by having theroof panel 82 and the ceiling panel 72 clamped together, whether by afastener 28 or otherwise secured, this also helps further ensure thatthe connection between the wall panel 50 and the ceiling panel 72 stayssecure. This is because the roof panel 82 presses down on the fastener28 and profile 14 on the ceiling panel 72. This is turn prevents thefastener 28 and the profile 14 that are on the ceiling panel 72 andconnected to the wall panel 50 from moving.

The entire building unit 10, in some embodiments, can be assembled witha minimal number of people and require minimal to no tools for assembly.In addition, the building unit 10 can be assembled in a minimal amountof time, such as 30 minutes.

The many panels described, such as the ceiling panels, the walls panels,the roof panels, and the floor panels, can be made from variousdifferent materials. For example, the panels can be made up of a seriesof different materials, such as having a foam core sandwiched betweentwo pieces of plywood. The panels can be structural insulated panels orstructural insulating panels (SIPs) or other types of composite buildingmaterials. In some embodiments the panels can be made up of a singlematerial, such as solid plywood. In addition, the panels can be coatedwith various different materials, such as a coating on the inside orwhat will be the inside of the building and a separate or the samecoating on the outside or what will be the outside of the building. Forexample, the panel can be made with a phenolic skin or otherresin-impregnated kraft paper, fiberboard siding, high impact plastic,metal, fiber reinforced plastic (FRP), etc. Some surfaces of the panelsmay also be covered with a polyurethane or polyurea coating. Othercoatings can also be used.

As will be understood, the building units 10 can be assembled such thatmultiple building units can be combined to create a larger structure, orthe building unit can be used or combined with other structures.

It should also be understood that the profiles 12, 14, 16 can be anydesired length. For example, profile 14 can extend the entire length ofa side of the wall section 5, or multiple profiles 14 can be used.Advantageously, all components of the building system 10 can be sized sothat they can be shipped together. For example, the profiles 12, 14, 16can be as long as or shorter than the panels 36, 50, 72.

Turning now to FIGS. 13 and 14, a shipping container or crate 40 isshown. The crate 40 can include a number of the panels 42, 44 that canbe connected to one another by various methods. For example, the panelscan have a series of slots 38 and be connected to one another with aseries of fasteners or clips 28 as described in Application 61/511,951,filed on Jul. 26, 2011. Inserts can be placed within the slots as alsodescribed in Application 61/511,951, filed on Jul. 26, 2011. Again, asbefore, only a limited number of clips 28 are shown, but it should beunderstood that all of the slots 30 can include a clip 28 and, in someembodiment an insert. It will be understood that clips of other typesand designs can also be used. The crate can be assembled, disassembledand stacked as also described therein. The crate can be any type ofcrate but is preferably a crate as described in Application 61/511,951,filed on Jul. 26, 2011. One or more profiles 12, 14, 16 can also be usedin the assembly of the crate 40. As shown in FIG. 14, a profile 12 canbe used to connect two panels 42, 44 together. Each side of the crate 40can use a single panel 42, 44, or more than one panel.

The building system 10 can be shipped within the crate 40. As can beseen in FIG. 13, the building system 10 is shown disassembled andstacked within the crate 40. Additional features, such as airconditioning units can also be shipped with the building system 10. Thecrate 40 can be sized and shaped according to the dimensions of thecomponents of the desired building system 10 when disassembled. Thoughit cannot be seen, the crate 40 can include a pallet type feature on thebottom of the crate or other transport structure or feature tofacilitate the handling and moving of the crate 40. The transportstructure or feature can support the crate in a stable fashion whilebeing lifted by a forklift, pallet jack, front loader, hoist, crane,etc.

In some embodiments, after the building system 10 has emptied from thecrate 40, the crate 40 can also be used as a building. For example, thecrate 40 can be used as a shelter, a shed, a bathroom, an out building,etc. As shown in FIG. 14, the crate 40 can be provided with a panel 44that includes a door 46. The panel 44 can form a part of the shippingcontainer 40 during shipping. Alternatively, an extra panel 44 with adoor 46 can be shipped inside the crate 40 to later replace one of thepanels 42. After replacement, the crate can be used as a building orstructure that has a door. Of course, it will be understood that thecrate 40 can also be used as a building or structure by simply removingone or more panels.

FIGS. 15-20 show another embodiment of a building system 10′. Numericalreference to components is the same as previously described, except thatone or more prime symbols (′) have been added to each reference numeral.Where such references occur, it is to be understood that the componentsare the same or substantially similar to previously-describedcomponents. It should be understood that the illustrated building systemincludes each of the features designated by the numbers used herein.However, as emphasized repeatedly herein, these features need not bepresent in all embodiments.

The building system 10′ is shown with three sections, a base unit orfoundation 3′, walls 5′ and roof 7′. As has been mentioned, the base 3′can take many forms. The base 3′ can use a system of modular beams 32′to support the building system 10′. The beams 32′ can raise the floorpanel(s) 36′ off of the ground. The beams 32′ may or may not be attachedto the floor panel(s) 36′ and may or may not be interconnected. Thebeams 32′ can be made of any of many different materials, such as metal,wood, and composite building materials. For example, the beams can bemade of, but not limited to, ¾″ plywood and coated with polyurea.

Looking now to FIG. 16, it can be seen that the beams 32′ can be modularto provide for any number of different lengths of beam. The beamsections 62, 64 can individually be the same length or differentlengths. In addition, the beam sections can be the substantially samelength or width as the floor panels 36′. As shown, the beam section 62is substantially the same length as the width of two floor panels, whilebeam section 64 is as long as one floor panel is wide. The beam 32′ canalso include beam section 66, 68 that can be end caps for the beam. Theend caps can close and/or essentially finish the beam, for example sothat the height of the beam is consistent along its length and so thatany open cavities are closed.

The different sections of the beam 32′ can be attached in many differentmanners. In some embodiments, the beam sections are slip fit togetherwith a mortise and tenon joint or with a tongue and groove joint. A beamsection 62, 64 can have a mortise hole 70 at one end and a tenon 60 atthe other end. This can allow any number of beam sections to beconnected. In some embodiments, some or all of the beam sections 66, 68can have only one of a mortise hole and a tenon on one end and the otherend can be a closed surface. The closed surface can define the end orend cap of the beam 32′. It will be understood that other configurationscan also be used. The beam sections 62, 64, 66, 68 are preferably heldto together by friction, but fasteners such as bolts may also be used.

The beams 32′ can be laid out as a foundation for the floor panels 36′.In some embodiments shims can be proved to help level the floor panels.The floor panels are preferable not fastened to the beams and can stayin place by friction. At the same time, certain uses or locations mayrequire a separate anchoring system, for example, if the building systemis to be used in a high wind area.

FIGS. 17-20 will now be used to describe the roof and/or ceiling 7′.FIG. 17 shows a modification of the ceiling panels 72′. In particular,rather than having large opening or holes, the ceiling panels 72′ havemuch smaller holes 74′. These smaller holes can still be used to attachto or provide additional features in the ceiling as has been described.For example, a fastener 28′ can extend through the hole 74′ to attach aceiling panel 82′ to the ceiling panel 72′. In addition, a ceiling plugor cover can also be used.

FIG. 18 shows another embodiment of a fastening system for use with theceiling and roof panels. In particular, a bolt 94 and washer or plate 92can be used to secure roof panel 82″ to the ceiling panel 72′. The boltcan be self threading, or can engage a nut 96 that has been attached tothe roof panel 82″.

Turning now to FIG. 19, a partially exploded view of the building system10′ is shown. FIG. 19 illustrates a cover 88 that can be used to placeon top of and/or surrounding the roof panels 82′. Looking back at FIG.15, it can be seen that the cover 88 can enclose the top of the buildingsystem 10′. This can include enclosing all or part of one or more of theroof panels 82′, wall panels 50′, profiles 14″, profiles 12′, profiles16″, fasteners 28′, and inserts 130′. In some embodiments, the sides ofthe cover 88 can extend down to the slots 38′ in the wall panels 50′. Asshown, the slots 38′ have an insert 130′ placed within them. In someembodiments the cover 88 can be used in addition to or instead of theroof panels 82′. For example, the cover 88 can surround and directlycover the ceiling panels 72′ without the use of separate roof panels82′. It will be understood that the ceiling panels 72, 72′ can also formthe roof without separate roof panels 82, 82′ and/or a cover 88.

The cover 88 can be made of any number of different materials and ispreferably waterproof. The cover can be a large sheet of strong,flexible, water-resistant or waterproof material. The cover can be madeof cloth, canvas, polyester, polyethylene, polypropylene, etc. In someembodiments the cover can comprise a tarpaulin or tarp.

The cover 88 can be connected to the rest of the building system in manyways. In some embodiments, the cover can form a tight fit over the roofand be held on by friction. Looking to FIG. 20, a rope or cord 90 mayalso be used to secure the cover 88. As shown, the rope 90 and cover canbe configured such that the rope is sewn or otherwise enclosed withinthe cover. In some embodiments, the rope and extend around the bottomperiphery of the cover. The cover 88 can include one or more holes 92through which the rope can extend. For example, the cover 88 can haveone or more holes 92 at the same locations on the buildings where thefasteners. The rope can be secured to one or more fasteners 28′. Forexample, the rope 90 can engage with the clip release feature 156′ onthe fastener 28′.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In addition, while a number of variations of the invention havebeen shown and described in detail, other modifications, which arewithin the scope of this invention, will be readily apparent to those ofskill in the art based upon this disclosure. It is also contemplatedthat various combinations or sub-combinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the invention. Accordingly, it should be understood thatvarious features and aspects of the disclosed embodiments can becombined with or substituted for one another in order to form varyingmodes of the disclosed invention. Thus, it is intended that the scope ofthe present invention herein disclosed should not be limited by theparticular disclosed embodiments described above, but should bedetermined only by a fair reading of the claims that follow.

Similarly, this method of disclosure, is not to be interpreted asreflecting an intention that any claim require more features than areexpressly recited in that claim. Rather, as the following claimsreflect, inventive aspects lie in a combination of fewer than allfeatures of any single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment.

What is claimed is:
 1. A building system comprising: a series a wallpanels, each having one or more wall slot; a series of floor panels eachhaving one or more floor slot; a series of ceiling panels each havingone or more ceiling slot; a first profile comprising two cavitiesextending along different sides of the profile, each cavity configuredto receive a panel from the same series together; a second profile forconnecting panels from one series to another series together, the secondprofile having a shape different from the first profile and comprisingtwo cavities positioned essentially perpendicular with one another, thefirst cavity configured to receive at least one of either the floorpanels or the ceiling panels, and the second cavity configured toreceive at least one of the wall panels such that in the assembledconfiguration the wall panel will rest on and be above the at least onefloor panel or the ceiling panel will rest on and be above the wallpanel; and a plurality of fastening clips, each clip configured tolockingly engage a wall slot at one end and one of either a wall slot, afloor slot, and a ceiling slot at the other end, wherein the buildingsystem does not require other fasteners besides the clips and profilesto hold the panels together.
 2. The building system of claim 1, whereinthe first profile has an I-beam shape with the two cavities being onopposite sides of the first profile.
 3. The building system of claim 1,wherein the two cavities of the first profile are angled at about 135degrees with respect to one another.
 4. The building system of claim 1,wherein the second profile has an “L” shape defining two cavitiesposition essentially perpendicular with one another.
 5. The buildingsystem of claim 2, wherein the second profile has an “L” shape definingtwo cavities position essentially perpendicular with one another.
 6. Thebuilding system of claim 1, further comprising a third profileconfigured to form a corner between two wall panels, the third profilehaving a central channel that runs along the length of the profile andtwo cavities with openings perpendicular to one another running alongthe length of the central channel.
 7. The building system of claim 1,wherein the second profile is configured to form a corner between twowall panels.
 8. The building system of claim 1, further comprising aplurality of inserts each configured to be placed within the one of awall slot, a floor slot, or a ceiling slot.
 9. The building system ofclaim 8, wherein the each clip of the plurality of clips is configuredto be positionable within two inserts at opposite ends of each clip. 10.A building system comprising: a series a wall panels; a series of floorpanels; a series of ceiling panels; a first profile being in the shapeof an I-beam for connecting panels for connecting panels from the sameseries together; a second profile for connecting panels from one seriesto another series together, the second profile having an “L” shapedefining two cavities position essentially perpendicular with oneanother, the first cavity configured to receive at least one of eitherthe floor panels or the ceiling panels, and the second cavity configuredto receive at least one of the wall panels such that in the assembledconfiguration the wall panel will rest on and be above the at least onefloor panels or the ceiling panel will rest on and be above the wallpanel; a plurality of clips configured to lockingly engage a wall panelat one end and one of either the wall panels, floor panels, and ceilingpanels at the other end, wherein the building system does not requireother fasteners besides the clips and profiles to hold the panelstogether.
 11. The building system of claim 10, further comprising athird profile configured to form a corner between two wall panels, thethird profile having a central channel that runs along the length of theprofile and two cavities with opening perpendicular to one anotherrunning along the length of the central channel.
 12. The building systemof claim 10, wherein the second profile is also configured to form acorner between two wall panels.
 13. The building system of claim 10,wherein: the series of wall panels further comprises one or more wallslot on each wall panel; the series of floor panels further comprisesone or more floor slot on each floor panel; the series of ceiling panelsfurther comprises one or more ceiling slot on each ceiling panel; andeach clip of the plurality of clips is configured to lockingly engage awall slot at one end and one of either a wall slot, a floor slot, and aceiling slot at the other end.
 14. The building system of claim 13,further comprising a plurality of inserts configured to be positionablewithin the one of the wall slots, floor slots, or ceiling slots whereineach of the clips of the plurality of clips is configured to bepositionable within two inserts at opposite ends of each individualclip.